Embossed floor covering



Aug.' 23, 1932. J c; MccAR'rHY 1,873,001

EMBOSSED FLOOR COVERING Filed 001'.. 3l, 1929 Paten-tedl Aug. 23, 1932 UNITED STATES PATEN 'P- lol-*Flca' J CLARENCE MCCARTBIY, OF'LANCASTEB, PENNSYLVANIA, .ASSIGNOR v'.120 ARMSTRONG CORK COMPANY,

or Lancasrna, vaina y Application led October 81, 1929. Serial No. 403,820.

This invention relates. to embossed floor coverings and is herein particularly described as applied to the manufacture of molded inlaid linoleum.

'f5 Linoleum and similar flexible hard surfaced floor coverings have always presented a hard appearance to the eye. In fact, one class of patterns which has beensingularly successful has been that in 1o simulated. Difficulty has also been experienced in getting a soft blending of the pattern elements one into the other. Y In straightlinelinoleum there is a clean, sharp line of demarcation between adj acent pattern elements. In unembossed molded inlaid linoleum the line of junction is wavy in 'char-v acter. This, however, is not a virtue'buta defect and does not lead to any blending of the adjacent colors. On the contrary, the line of distinction is vmarked butsuch line itself is of an objectionable character. 1

Because of these defects it has heretofore been impossible to obtain certain `desirable decorative effects in linoleum 'and' the like.

There is a demand for patterns wherein there is a soft blending of one color into another and wherein there is a surface texture with the pattern un-obtrusively appearing therethrough. Great difficulty is experienced in obtaining such an effect, but I have found that by the provision of tuft-like crests over the surface of the linoleum very desirable effects can be obtained. Preferably these crests are relatively small, averaging, say, -fg of an inch across, andbeing arranged in a haphazard manner over the entire surface of the goods. Such tuft-like crests may comprise an irregular series of small humps which are serrated so as to soften the effect.

With this type of embossing it is relatively easy to obtain a continuous effect of the character desired.- In the molded inlaid process, which is intermittent in its nature, the lembossing is obtained by a reciprocable die which works on a limited length only of the material. I have found that contrary to previous experience it is possible with this type of embossing to overlap successive embossed portions without destroying the eect and without the overlap showing. This is of which tiling is 'importance because any break in the character of the texture imparted to the material, as would result if nonoverlapping portions were embossed by such a die, would destroy the eii'ect which it is necessary to obtain. The invention finds particular value in the molded inlaid Erocess where thev irregular line of juncture etween adjacent pattern elements cooperates with the small tuft-like crests to produce the blending effect. j In the accompanying drawing, illustrat? ing the present preferred embodiment of the invention as applied to 'a pattern of the hooked rug type,

Figure 1 is a to plain moldedinlai linoleum; y Figure 2 is a plan view of the same piece 'after itv has been embossed according to my invention; and v v y Figure 3 is a longitudinal section through the embossed goods.

The linoleum shown in the drawing is made'v by the molded inlaid process,l granulated planiview of a piece :of 465 color being supplied through stencils onto a backmg 2 so as to4 form a vari-colored pattern. As shown in Figure 1, the several pattern elements are separated by lines of juncture 8 of the-wavy irregular character inherent in the molded inlaid process. Itwill be noted from Figure 1 that the general eii'ect of the process is to give a pattern with definite monotone color areas which distinguish v sharply from one another, but which are separated along wavy lineswhich are themselves objectionable in appearance. The material itself is smooth and hard surfaced and presentsa cold, hard appearance to the eye.

Figure2 shows the same piece 4of materialafter it has been embossed according to` my invention. It will be noted that the entire regular series of small crests 4. Each crest is serrated, vas indicated at 5. These serrations are quite shallow but are very effective for softening the general tone of the material. The serrations extend in different directions in different crests, but lie generally parallel in any given crest.

The several crests formed by the emboss` g are tuft-like in character and somewhat,`

.surface of the goods is covered with an ir- III) reminiscent of carpet, although 'ving a new and highly ornamental effect. he colors of the pattern are subdued and in eneral there is a tendenc for the colors to b end one lnto thev other.- he irregular jluicture lines between pattern elements follow an uphill and downdale course over the embossed surface of the linoleum, thus doing away' with any sharp lines of separation -between adjacent pattern elements.

Molded inlaid machines are designed to `ve a repeat length of 54 inches, and heretofdre embossing presses'have been provided with dies effective for embossing a 54 inch length at one time. In the present case, however, I have found it highly desirable to emboss a slightly greater length so that when the goods 1s moved forward and the embossing die is again lowered, it overlaps a portion of the previously embossed material and re-embosses it. I have found that with a surface embossing of the character herein described the overla does not show and the eneral effect is o a continuous tufted surace without any change or interru tion in the surface character thereof. It is t us possible to produce long lengths of the material without any breaks 1n the embossing.

While it is possible to secure the continu.- ous embossed effect with relatively large and separated embossed interliners, such as are used in tile patterns, I have found that allover embossed patterns are difficult toproduce. If it is attempted to emboss\exactl 54 inches and then emboss an adjacent 54 inc es, the line of separation shows very distinctly and destro s the effect; while if it is attempted, with ot er all-over embossed patterns, to overlap the embossing, as herein described, such overlapping shows very clearly, and the net result 'is that a band of material having a oor decorative effect is produced every 54 lnches. However, as above stated, it is possible, where tuft-like crests are provided, to overlap the die without such overlapping being evident in the final product.

I have illustrated and described my invention as applied to one type of pattern. It will be understood, however, that it is not thus limited but may be otherwise embodied orpracticed within the scope of the following claims.

I claim; v

1'. In the manufacture of fiexible hard surfaced iloor coverings, the step consisting in forming a series of small serrated humps irregularly arranged over 'the surface thereof;

2. In the manufacture of flexible hard surfaced iioor coverings, the steps consisting in forming a pattern, and forming an irregular series of small serrated humps over the surface thereof, the serrations running in different directions in different humps.

3. In the manufacture of iexible hard surfaced floor coverings, the steps consisting in forming a'pattern, and forming an irregular series of small serrated humps over the surface thereof,wthe serrations runnin in different directions in different humps ut running generally parallel in any hump.

4. In faced Hoor coverings, the step consisting in producing serrated humps over substantially sessing irregularities characteristic of molded inlaid linoleum, and having crests embossed over the surface thereof. j

8. As a new article of manufacture, a flexible hard surfaced floor covering having small serrated humps over the surface thereof, the serrations running in different directions in different humps.v

9. As a new article of manufacture, a ilexthe manufacture of flexible hard surible hard surfaced door covering having small serrated humps over the surface thereof, the serrations running in different directions in different humps, but running generally parallel in any hump.

10. In the manufacture of flexible hard surfaced fioor coverings, the step consisting in forming an irregular series of small serrated humps over'the surface thereof, the serrations running in different directions in different humps.

11. In the manufacture of flexible hard surfaced ioor coverings, thel steps consisting in forming a series of crests substantially covering a portion of the surface of the material, then forming a like 4series of crests over an adjacent portion of the material, and overlapping such portions so that crests originally formed in the first portion are reformed'in the secondportion.

12. As a new article of manufacture, a exible hard surfaced floor covering having a plurality of crests embossed over the surface thereof, the individual crests being small in crosswise dimension and being arranged in a haphazard manner over substantially the entire surface of they goods.

In testimony whereof I have hereunto set my hand.

J CLARENCE MCCARTHY.

CERTIFICATE ot' CRRECTION.A

Patent No. 1,873,001. Augusta'. 1932,.,

I CLARENCE McCARTHY.

It is hereby certified that error appears in the printed specification vof-fthe above numbered patent requiring correction as' follows"- Pa'rge'Z, l'|inef1, claim 4, strike outthe word "substantially", and linel ,75. strike' out the 'word-"clima4 tire"; and that the said Letters Patentshould-be'readwith 4these correctionstherein that the same may conform to the record ofthe casein the Patent 0ffice.

Signed and sealed this 22nd day of November, A. D. 1932.

M. J. Moore, (Seal) Act-ing Commissioner of lltents. 

